Experiment bench suitable for whole vehicle waste heat recovery system and test method thereof

Abstract

The invention provides an experiment bench suitable for a whole vehicle waste heat recovery system and a testing method thereof.The experiment bench comprises an engine whole vehicle, a waste heat recovery system and a measurement and control system, and a preheater in the waste heat recovery system is connected with a hydraulic retarder pipeline in the engine whole vehicle through a rigid pipeline; a flue gas heat exchanger in the waste heat recovery system is connected with a waste gas exhaust end pipeline in the whole engine through a rigid pipeline, and is used for controlling the on-off of each pipeline through the waste heat recovery system and a valve in the whole engine so as to realize the start and stop of the system experiment bench; the measurement and control system is arranged on pipelines in the whole engine and the waste heat recovery system and used for obtaining operation parameters of the whole engine and the waste heat recovery system, and the design difficulty of an experiment test scheme of the experiment bench of the waste heat recovery system is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of whole vehicle experiment test, in particular to a whole vehicle waste heat recovery system experiment bench and a test method thereof. BACKGROUND

[0002] With the rapid development of today's technology and the improvement of environmental laws and regulations, the core goal of the development of internal combustion engine technology has been focused on improving its thermal efficiency and reducing fuel consumption. For the energy generated by engine fuel combustion, a part of it is converted into effective output power by reciprocating piston and rotating crankshaft through in-cylinder gas expansion, and the remaining energy, except for friction loss, is all dissipated through cylinder sleeve water, high-temperature exhaust gas, supercharged air cooling water and other ways, in which the heat carried away by cylinder sleeve water and exhaust gas accounts for about 50% of the total heat value. The exhaust gas waste heat recovery system is a new energy technology that can improve the thermal efficiency of the engine to improve the utilization rate of fuel energy and reduce carbon dioxide emissions. The exhaust gas waste heat recovery system based on organic Rankine cycle is the most popular and highest practical engineering application rate technology. Its principle is to recycle the available heat of engine coolant, exhaust gas and other heat through organic working fluid circulation, and convert the heat into useful output power through a turbine expander. The exhaust gas waste heat recovery system is an innovative and effective technical means to improve the energy efficiency of existing engines, especially the thermal efficiency of the power core engine, and has the technical potential to greatly save fuel consumption.

[0003] For the waste heat recovery system, most of the research directions of colleges and enterprises currently stay at the system level, hoping to make it have as high effective output power as possible through research on system configuration, components and working medium, etc. However, there are few experiments and tests of the whole vehicle level with the waste heat recovery system. The main reason is that there are many components of the waste heat recovery system and the space of the whole vehicle is limited, so how to play the potential of the waste heat recovery system in the limited space is a technical difficulty, and the layout scheme needs to consider the coupling and design of the waste heat recovery system and the original whole vehicle system. In addition, the waste heat recovery system needs precise and multiple control when it is running, and the experimental test process needs to be standardized and orderly to ensure that the system can work stably and safely to generate electricity. In summary, the existing waste heat recovery system test bench lacks coupling design with the whole vehicle system, making the design of the experimental test scheme of the waste heat recovery system experiment bench difficult.

[0004] In view of this problem, the present application provides a whole vehicle waste heat recovery system experiment bench and a test method thereof to solve the above problems. SUMMARY

[0005] The application provides a vehicle waste heat recovery system test bench and a test method thereof to solve the problems in the prior art.

[0006] The first aspect of the application provides a vehicle waste heat recovery system test bench, which comprises an engine vehicle, a waste heat recovery system and a measurement and control system.

[0007] Optionally, the waste heat recovery system comprises a preheater, a regenerator, a condenser, a flue gas heat exchanger, a turbine expander, a working medium pump and a liquid storage tank.

[0008] Further, the measurement and control system comprises a power analyzer, control valves, and parameter acquisition sensors, wherein the power analyzer is used to monitor and analyze the work done by the turboexpander; the control valves comprise a first control valve arranged in a pipeline between the liquid storage tank and the working medium pump, a second control valve arranged in a pipeline between the turboexpander and the regenerator, a third control valve arranged in a bypass pipeline of the turboexpander, a fourth control valve arranged in a pipeline between the flue gas heat exchanger and the turboexpander, a first bypass control valve arranged in a bypass pipeline of the flue gas heat exchanger in the engine vehicle, and a second bypass control valve arranged in a bypass pipeline of the preheater in the engine vehicle; and the parameter acquisition sensors are arranged in a pipeline between the preheater and the engine vehicle, a pipeline between the preheater and the hydraulic retarder, a pipeline between the flue gas heat exchanger and the engine vehicle, a pipeline between the preheater and the flue gas heat exchanger, a pipeline between the flue gas heat exchanger and the turboexpander, a pipeline between the turboexpander and the regenerator, a pipeline between the regenerator and the preheater, a pipeline between the working medium pump and the regenerator, a pipeline between the regenerator and the condenser, and a pipeline between the condenser and the liquid storage tank.

[0009] The second aspect of the present application provides a test method suitable for the whole vehicle waste heat recovery system test bench, which is based on the first aspect of the present application and comprises the following steps: checking the engine vehicle, the waste heat recovery system, the internal devices of the measurement and control system, and the connecting pipelines, checking the connecting pipelines between the engine vehicle and the waste heat recovery system, confirming that the engine vehicle, the waste heat recovery system, the internal devices of the measurement and control system, and the connecting pipelines are normal, and confirming that the connecting pipelines between the engine vehicle and the waste heat recovery system are normal; starting the diesel engine vehicle to run, setting the vehicle condition in an idle state, and maintaining stable operation of the waste heat recovery system before starting the engine vehicle and in the idle state; adjusting the whole vehicle running parameters to the target working condition, testing the waste heat recovery system, and recording the test results; stopping the waste heat recovery system and the diesel engine vehicle to end the test after the performance test.

[0010] Optionally, the confirmation that the engine vehicle, the waste heat recovery system, the internal devices of the measurement and control system, and the connecting pipelines are normal, and the confirmation that the connecting pipelines between the engine vehicle and the waste heat recovery system are normal specifically comprise: the engine vehicle technical inspection result confirms that the vehicle condition is good, and the result of at least one vehicle detection software diagnosing the vehicle is that the vehicle has no fault; The inspection result of the connection pipeline of each component in the waste heat recovery system is no obvious leakage and damage, and the inspection result of the electrical wiring and signal acquisition of each component in the waste heat recovery system is normal function; The inspection result of each component in the measurement and control system is normal function of the equipment; The inspection result of the connection pipeline between the waste heat recovery system and the engine vehicle is no obvious leakage and damage; The opening and closing states of each control valve in the waste heat recovery system and the engine vehicle are in the preset opening and closing state.

[0011] Further, the preset opening and closing state is whether the first control valve, the second control valve, the third control valve and the fourth control valve are in the closed state, and whether the first bypass control valve and the second bypass control valve are in the open state.

[0012] Alternatively, the diesel engine vehicle is started to run, and the vehicle condition is set in the idle state until the waste heat recovery system maintains stable operation before the engine vehicle is started and in the idle state, specifically: The first control valve and the second control valve in the waste heat recovery system are opened in turn, and the working fluid pump is started, and it is checked whether the parameters of the organic working fluid and the condensate water circulating in the pipeline of the waste heat recovery system are in the first preset range; After the inspection result is passed, the engine vehicle is started to run, and the vehicle condition is set in the idle state, and the first bypass control valve and the second bypass control valve are closed; It is checked whether the parameters in the pipeline connected with the engine vehicle in the waste heat recovery system are in the second preset range. If the parameters of the organic working fluid and the condensate water circulating in the pipeline of the waste heat recovery system are in the first preset range, and the parameters in the pipeline connected with the engine vehicle in the waste heat recovery system are in the second preset range, the waste heat recovery system maintains stable operation before the engine vehicle is started and in the idle state. The first pipeline parameter value is greater than the second pipeline parameter value. The first pipeline parameter value is the parameter value in the pipeline connected with the engine vehicle in the waste heat recovery system when the waste heat recovery system is not running. The second pipeline parameter value is the parameter value in the pipeline connected with the engine vehicle in the waste heat recovery system when the engine vehicle is running.

[0013] Alternatively, the vehicle operating parameters are adjusted to the target working condition, and the waste heat recovery system is tested and experimental records are recorded, specifically including: During the adjustment of the vehicle operating condition, with the heat interaction between the preheater and the flue gas heat exchanger in the waste heat recovery system and the engine vehicle, the working fluid pump speed in the waste heat recovery system is adjusted synchronously to accelerate the flow rate of the organic working fluid in the waste heat recovery system, so as to maintain the parameters of the organic working fluid and the condensate water circulating in the pipeline of the waste heat recovery system in the third preset range; After the parameters of the organic working medium and the condensate water circulating in the pipeline of the waste heat recovery system meet the opening condition of the turboexpander, the second control valve is opened, the fourth control valve is gradually opened according to a preset opening adjustment range, and the third control valve is gradually closed according to a preset opening adjustment range; In the case that the turboexpander works normally, the third control valve is completely closed, and the waste heat recovery system enters the power generation working mode; In the case that the vehicle operating condition is stable at the target parameter, the waste heat recovery system is adjusted to the power generation working mode and maintained stable operation for a preset time length, and the power generation capacity of the turboexpander is within a stable fluctuation range; The working medium pump speed is adjusted to obtain the variation of the operating performance parameters of the waste heat recovery system within the safe operation range of the turboexpander at different speeds.

[0014] Further, the operating performance parameters of the waste heat recovery system include the power generation capacity of the turboexpander and the parameters of the organic working medium and the condensate water circulating in the pipeline of the waste heat recovery system.

[0015] Optionally, after the performance test is completed, the waste heat recovery system and the diesel engine vehicle are stopped to end the test, and the specific process is as follows: After the performance test is completed, the third control valve is gradually opened according to a preset opening adjustment range, and then the opening of the fourth control valve is gradually reduced according to a preset opening adjustment range until the turboexpander is stopped, and the second control valve is closed; The vehicle driving speed is gradually reduced until the vehicle is stopped, the working medium pump speed of the waste heat recovery system is adjusted to the parameters of the waste heat recovery system within a fourth preset range, the working medium pump is stopped, the first control valve and the third control valve are completely closed, and the first bypass control valve and the second bypass control valve are completely opened; After the experiment is completed, it is confirmed again that the engine vehicle, the waste heat recovery system, the internal devices of the measurement and control system and the connecting pipelines are normal, and it is confirmed again that the connecting pipelines between the engine vehicle and the waste heat recovery system are normal.

[0016] The technical scheme adopted by the present application includes the following technical effects: 1、The preheater in the waste heat recovery system is connected with the hydraulic retarder pipeline in the engine vehicle through a rigid pipeline, the flue gas heat exchanger in the waste heat recovery system is connected with the exhaust gas discharge end pipeline in the engine vehicle through a rigid pipeline, the on-off of each pipeline is controlled through the waste heat recovery system and the valves in the engine vehicle to realize the start-stop of the system experiment bench, and the measurement and control system is arranged in the pipelines in the engine vehicle and the waste heat recovery system to obtain the operating parameters of the engine vehicle and the waste heat recovery system, thereby effectively solving the problem that the design difficulty of the experimental test scheme of the waste heat recovery system experiment bench is large due to the prior art, and effectively reducing the design difficulty of the experimental test scheme of the waste heat recovery system experiment bench.

[0017] 2、The technical scheme of the present application, the measuring and controlling system comprises a power analyzer, control valves and parameter acquisition sensors, the power analyzer is arranged on the side of the turbo expander for monitoring and analyzing the work done by the turbo expander; the control valves comprise a first control valve arranged on the pipeline between the liquid storage tank and the working medium pump, a second control valve arranged on the pipeline between the turbo expander and the regenerator, a third control valve arranged on the bypass pipeline of the turbo expander, a fourth control valve arranged on the pipeline between the flue gas heat exchanger and the turbo expander, a first bypass control valve arranged on the bypass pipeline of the flue gas heat exchanger in the engine vehicle, and a second bypass control valve arranged on the bypass pipeline of the preheater in the engine vehicle; the parameter acquisition sensors are arranged on the pipeline between the preheater and the engine vehicle, the pipeline between the preheater and the hydraulic retarder, the pipeline between the flue gas heat exchanger and the engine vehicle, the pipeline between the preheater and the flue gas heat exchanger, the pipeline between the flue gas heat exchanger and the turbo expander, the pipeline between the turbo expander and the regenerator, the pipeline between the regenerator and the preheater, the pipeline between the working medium pump and the regenerator, the pipeline between the regenerator and the condenser, and the pipeline between the condenser and the liquid storage tank, so that the operating parameter conditions of each pipeline in the engine vehicle and the waste heat recovery system can be obtained.

[0018] 3、The technical scheme of the present application not only confirms that the engine vehicle, the waste heat recovery system, the internal devices of the measuring and controlling system and the connecting pipelines are normal, but also confirms that the connecting pipelines between the engine vehicle and the waste heat recovery system are normal, thereby ensuring the effectiveness of the experimental bench test of the waste heat recovery system.

[0019] 4、The technical scheme of the present application checks whether the parameters of the organic working medium and the condensate water circulating in the pipelines in the waste heat recovery system are in a first preset range; after the checking result is passed, the engine vehicle is started to run, the vehicle condition is set in an idle state, and the first bypass control valve and the second bypass control valve are closed; if the parameters of the organic working medium and the condensate water circulating in the pipelines in the waste heat recovery system are in the first preset range, and the parameters in the pipelines connected with the engine vehicle in the waste heat recovery system are in a second preset range, the waste heat recovery system is maintained in stable operation before the engine vehicle is started and in the idle state, wherein the parameter value in the first pipeline is greater than the parameter value in the second pipeline, the parameter value in the first pipeline is the parameter value in the pipelines connected with the engine vehicle in the waste heat recovery system when not running, and the parameter value in the second pipeline is the parameter value in the pipelines connected with the engine vehicle in the waste heat recovery system when the engine vehicle is running; the engine vehicle waste heat recovery system experimental bench can be safely started, the vehicle can be quickly brought into the driving state, and the waste heat recovery system can be maintained in stable operation.

[0020] 5. In the technical solution of this invention, during the adjustment of vehicle operating conditions, as the heat exchangers and flue gas exchangers in the waste heat recovery system interact with the engine and the entire vehicle, the speed of the working fluid pump in the waste heat recovery system is simultaneously adjusted to accelerate the flow rate of the organic working fluid inside the waste heat recovery system. When the turbine expander is working normally, the third control valve is completely closed, and the waste heat recovery system enters the power generation mode. When the vehicle operating conditions are stable at the target parameters, the waste heat recovery system maintains stable operation for a preset time after adjusting to the power generation mode, and the power generation of the turbine expander is within a stable fluctuation range. By adjusting the speed of the working fluid pump, the changes in the operating performance parameters of the waste heat recovery system at different speeds within the safe operating range of the turbine expander are obtained. The waste heat recovery system can enter the power generation mode and follow the changes in its operating parameters under different vehicle driving conditions, thereby ensuring that the vehicle and the waste heat recovery system are in a safe, stable, controllable, and monitorable state throughout the entire experiment. Because the waste heat recovery vehicle experiment steps are complex, the system is coupled, and the scheme design is difficult, the correct experimental test process and operation sequence are crucial; otherwise, it may cause experimental test failure or even damage to components.

[0021] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit the invention. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the structure of the experimental platform in Embodiment 1 of the present invention; Figure 2 This is a flowchart illustrating the method of Embodiment 2 in the present invention. Detailed Implementation

[0024] To clearly illustrate the technical features of this solution, the invention will be described in detail below through specific embodiments and in conjunction with the accompanying drawings. The following disclosure provides many different embodiments or examples for implementing different structures of the invention. To simplify the disclosure of the invention, components and arrangements of specific examples are described below. Furthermore, reference numerals and / or letters may be repeated in different examples. This repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. It should be noted that the components illustrated in the drawings are not necessarily drawn to scale. Descriptions of well-known components, processing techniques, and processes are omitted in this invention to avoid unnecessarily limiting the invention.

[0025] Example 1 like Figure 1 As shown, the present invention provides a test bench for a vehicle waste heat recovery system, comprising: an engine vehicle, a waste heat recovery system, and a measurement and control system. The preheater in the waste heat recovery system is connected to the hydraulic retarder pipeline in the engine vehicle via a rigid pipeline. The flue gas heat exchanger in the waste heat recovery system is connected to the exhaust gas discharge pipeline in the engine vehicle via a rigid pipeline. The test bench is used to start and stop the system by controlling the opening and closing of each pipeline through valves in the waste heat recovery system and the engine vehicle. The measurement and control system is installed on the pipelines in the engine vehicle and the waste heat recovery system to acquire the operating parameters of the engine vehicle and the waste heat recovery system.

[0026] The waste heat recovery system includes a preheater, a regenerator, a condenser, a flue gas heat exchanger, a turboexpander, a working fluid pump, and a storage tank. The preheater exchanges heat with the engine coolant flowing into the hydraulic retarder under the action of the organic working fluid flowing out of the regenerator. The flue gas heat exchanger exchanges heat with the high-temperature exhaust gas emitted by the engine under the action of the organic working fluid flowing out of the preheater. The turboexpander performs work under the action of the organic working fluid flowing out of the flue gas heat exchanger and transports the heat-exchanged organic working fluid to the regenerator. The energy generated by the preheater and the flue gas heat exchanger is output as mechanical energy or electrical energy through work. The working fluid pump pumps the organic working fluid stored in the storage tank into the regenerator. The regenerator receives the heat from the high-temperature organic working fluid at the outlet of the expander and transports the recovered heat to the condenser for condensation through the recovered organic working fluid. The condenser condenses the organic working fluid at the outlet of the regenerator and transports the condensed organic working fluid to the storage tank. The organic working fluid circulates in the vehicle waste heat recovery system, entering the preheater to exchange heat with the diesel engine coolant, and then enters the flue gas heat exchanger to exchange heat with the high-temperature exhaust gas emitted by the diesel engine. The energy generated is used to perform work through the turbine expander to output effective mechanical energy or electrical energy.

[0027] The measurement and control system includes a power analyzer, control valves, and parameter acquisition sensors. The power analyzer, located in the laboratory monitoring room, is used to monitor and analyze the work done by the turbine expander. The control valves include a first control valve (valve 1, working fluid pump inlet valve) located in the pipeline between the liquid storage tank and the working fluid pump; a second control valve (valve 2, turbine expander outlet valve) located in the pipeline between the turbine expander and the regenerator; a third control valve (valve 3, turbine expander bypass valve) located in the turbine expander bypass pipeline; a fourth control valve (valve 4, turbine expander inlet valve) located in the pipeline between the flue gas heat exchanger and the turbine expander; and a first bypass control valve located in the flue gas heat exchanger bypass pipeline in the engine vehicle. Valve (valve 5, flue gas heat exchanger bypass valve), second bypass control valve (valve 6, preheater bypass valve) installed in the preheater bypass pipeline of the engine vehicle, parameter acquisition sensors are respectively installed in the pipeline between the preheater and the engine vehicle, the pipeline between the preheater and the hydraulic retarder, the pipeline between the flue gas heat exchanger and the engine vehicle, the pipeline between the preheater and the flue gas heat exchanger, the pipeline between the flue gas heat exchanger and the turbine expander, the pipeline between the turbine expander and the regenerator, the pipeline between the regenerator and the preheater, the pipeline between the working fluid pump and the regenerator, the pipeline between the regenerator and the condenser, and the pipeline between the condenser and the liquid receiver.

[0028] Specifically, the parameter acquisition sensors can be temperature sensors, pressure sensors, and flow meters. These include temperature and pressure sensors installed in pipelines between the preheater and the engine / vehicle; temperature and pressure sensors installed in pipelines between the preheater and the hydraulic retarder; temperature and pressure sensors installed in pipelines between the engine exhaust (exhaust gas) output pipeline and the flue gas heat exchanger; temperature and pressure sensors installed in pipelines between the flue gas heat exchanger and the engine exhaust gas recovery pipeline; temperature and pressure sensors installed in pipelines between the preheater and the flue gas heat exchanger; temperature and pressure sensors installed in pipelines between the flue gas heat exchanger and the turbine expander; temperature and pressure sensors installed in pipelines between the turbine expander and the regenerator; temperature and pressure sensors installed in pipelines between the regenerator and the preheater; flow meters installed in pipelines between the working fluid pump and the regenerator; temperature and pressure sensors installed in pipelines between the regenerator and the condenser; and temperature and pressure sensors installed in pipelines between the condenser and the receiver tank.

[0029] In this embodiment, the engine vehicle is a diesel engine vehicle, used for normal driving and providing a heat source for the waste heat recovery system. The engine's hydraulic retarder outlet connects to the engine coolant, which exchanges heat with the preheater in the waste heat recovery system. The high-temperature exhaust gas from the exhaust pipe connects to the flue gas heat exchanger in the waste heat recovery system for heat exchange. The waste heat recovery system recovers energy from the diesel engine coolant and exhaust gas, and outputs effective power. The monitoring and control system monitors the waste heat recovery system and collects data.

[0030] In this invention, the preheater in the waste heat recovery system is connected to the hydraulic retarder pipeline in the engine vehicle via a rigid pipeline, and the flue gas heat exchanger in the waste heat recovery system is connected to the exhaust gas discharge pipeline in the engine vehicle via a rigid pipeline. This connection is used to control the on / off state of each pipeline through valves in the waste heat recovery system and the engine vehicle, thereby starting and stopping the system test bench. The measurement and control system is installed in the pipelines of both the engine vehicle and the waste heat recovery system to acquire their operating parameters. This ensures that the diesel engine in the vehicle equipped with the waste heat recovery system can start and operate normally and undergo performance testing. This effectively solves the problem of high design difficulty in experimental testing schemes for waste heat recovery system test benches caused by existing technologies, and effectively reduces the design difficulty of experimental testing schemes for waste heat recovery system test benches.

[0031] The measurement and control system in this invention includes a power analyzer, control valves, and parameter acquisition sensors. The power analyzer is located on the turbine expander side and is used to monitor and analyze the work done by the turbine expander. The control valves include a first control valve located in the pipeline between the liquid storage tank and the working fluid pump, a second control valve located in the pipeline between the turbine expander and the regenerator, a third control valve located in the turbine expander bypass pipeline, a fourth control valve located in the pipeline between the flue gas heat exchanger and the turbine expander, a first bypass control valve located in the flue gas heat exchanger bypass pipeline in the engine vehicle, and a second bypass control valve located in the preheater bypass pipeline in the engine vehicle. The parameter acquisition sensors are respectively installed in the pipelines between the preheater and the engine / vehicle, between the preheater and the hydraulic retarder, between the flue gas heat exchanger and the engine / vehicle, between the preheater and the flue gas heat exchanger, between the flue gas heat exchanger and the turbine expander, between the turbine expander and the regenerator, between the regenerator and the preheater, between the working fluid pump and the regenerator, between the regenerator and the condenser, and between the condenser and the liquid receiver. These sensors can acquire the operating parameters of the engine / vehicle and various pipelines in the waste heat recovery system.

[0032] Example 2 like Figure 2As shown, the present invention also provides a testing method suitable for a test bench for a vehicle waste heat recovery system, which is based on a test bench for a vehicle waste heat recovery system described in Embodiment 1, and includes: S1, obtain the inspection status of the internal components and connecting pipes of the engine vehicle, waste heat recovery system, and measurement and control system, obtain the inspection status of the connecting pipes between the engine vehicle and the waste heat recovery system, confirm that the internal components and connecting pipes of the engine vehicle, waste heat recovery system, and measurement and control system are all normal, and confirm that the connecting pipes between the engine vehicle and the waste heat recovery system are all normal. S2, start the diesel engine and run the vehicle, set the vehicle to idle, until the waste heat recovery system maintains stable operation before the engine starts and at idle. S3, adjust the vehicle's operating parameters to the target operating conditions, and test and record the waste heat recovery system; S4: After the performance test is completed, the waste heat recovery system and the diesel engine of the vehicle will be shut down to end the experiment.

[0033] In step S1, which is the experimental preparation stage, a safety check is performed before starting the diesel engine vehicle and waste heat recovery system to ensure that all equipment components, valves, and pipeline connections are normal before starting. Specifically, this includes confirming that the internal components and connecting pipelines of the engine vehicle, waste heat recovery system, and measurement and control system are normal, and confirming that the connecting pipelines between the engine vehicle and waste heat recovery system are normal. The engine and vehicle technical inspection (technical inspection and maintenance of the diesel engine vehicle) results confirm that the vehicle is in good condition, and at least one vehicle testing software (such as INCA, CAN tool or six-in-one diagnostic tool) diagnoses the vehicle and finds no faults. The inspection of the connecting pipelines of each component in the waste heat recovery system (reliability inspection of the connecting pipelines of each component in the waste heat recovery system) showed no obvious leakage or damage. The inspection of the electrical wiring and signal acquisition of each component in the waste heat recovery system (inspection of the electrical wiring and signal acquisition of the working fluid pump, turbine generator and electrically controlled valves of each component in the waste heat recovery system to ensure that the relevant equipment functions normally) showed that the functions were normal. The inspection of each component in the measurement and control system (checking the electrical wiring and signal acquisition of the power analyzer, valves, temperature sensors, pressure sensors, flow meters, etc. in the measurement and control system, and checking whether the measurement and control communication and the readings at the measuring points are normal) showed that the equipment functions normally. The inspection of the connection pipeline between the waste heat recovery system and the engine vehicle (inspecting the connection between the engine aftertreatment exhaust pipeline and the waste heat recovery system flue gas heat exchanger to ensure reliable connection) showed no obvious leakage or damage. The waste heat recovery system and the control valves in the engine and vehicle are in the preset open / closed state.

[0034] Specifically, the preset open / closed states are whether the first control valve, the second control valve, the third control valve, and the fourth control valve are in the closed state, and whether the first bypass control valve and the second bypass control valve are in the open state.

[0035] Step S2 is the system startup phase, which involves checking the working status of the waste heat recovery system after the vehicle is started to ensure stable operation. Specifically, the diesel engine is started and the vehicle is set to idle speed until the waste heat recovery system maintains stable operation before the engine starts and at idle speed. S21, open the first control valve and the second control valve in the waste heat recovery system in sequence and start the working fluid pump to check whether the parameters (flow rate, pressure, temperature) of the organic working fluid and condensate circulating in the pipeline of the waste heat recovery system are within the first preset range. S22, after the inspection results are passed, start the engine and run the whole vehicle, set the vehicle condition to idle speed, and close the first bypass control valve and the second bypass control valve. S23, check whether the parameters (flow rate, pressure, temperature) in the pipelines connected to the engine and vehicle in the waste heat recovery system are within the second preset range. If the parameters of the organic working fluid and condensate circulating in the pipelines of the waste heat recovery system are within the first preset range, and the parameters in the pipelines connected to the engine and vehicle in the waste heat recovery system are within the second preset range, then the waste heat recovery system will maintain stable operation before the engine and vehicle starts and at idle. The values ​​of the first pipeline parameters are greater than the values ​​of the second pipeline parameters. The first pipeline parameter values ​​are the values ​​of the pipelines connected to the engine and vehicle in the waste heat recovery system when the engine and vehicle are not running. The second pipeline parameter values ​​are the values ​​of the pipelines connected to the engine and vehicle in the waste heat recovery system when the engine and vehicle are running. That is, because the waste heat recovery system is connected to the vehicle heat source and heat transfer begins, the pressure, temperature, and flow rate of the working fluid in the pipeline are all higher than when the system is not running.

[0036] In step S3, which is the performance testing phase, the vehicle operating parameters are adjusted to the required target operating conditions, and the waste heat recovery system is tested and the results are recorded. Specifically, adjusting the vehicle operating parameters to the target operating conditions and testing and recording the waste heat recovery system includes: S31, During the vehicle operation condition adjustment, as the heat exchanger of the preheater and flue gas heat exchanger in the waste heat recovery system interacts with the engine and the whole vehicle, the speed of the working fluid pump in the waste heat recovery system is adjusted synchronously to accelerate the flow rate of the organic working fluid inside the waste heat recovery system, thereby maintaining the parameters of the organic working fluid and condensate circulating in the pipeline of the waste heat recovery system within the third preset range. Specifically, after the waste heat recovery system starts normally, the diesel engine and vehicle are adjusted to the operating conditions required by the experimental plan. Experimental data are recorded after the waste heat recovery system stabilizes. During the adjustment of vehicle operating conditions, as the vehicle's operating conditions gradually increase, the heat exchange between the waste heat recovery preheater and the flue gas heat exchanger and the entire vehicle increases. At this time, it is necessary to simultaneously adjust the speed of the working fluid pump in the waste heat recovery system (generally increasing the speed by 50 rpm each time, but appropriate adjustments need to be made based on the performance of the working fluid pump and the vehicle's operating conditions) to accelerate the flow rate of the working fluid inside the waste heat recovery system, thereby maintaining the flow rate, pressure, and temperature of the working fluid and condensate circulating in the system pipelines within a reasonable range (this data range depends on the waste heat recovery performance parameters and should generally be within the optimal operating range of each system component).

[0037] S32, after the parameters of the organic working fluid and condensate circulating in the pipeline of the waste heat recovery system meet the start-up conditions of the turbine expander, open the second control valve, gradually open the fourth control valve according to the preset opening adjustment range, and gradually close the third control valve according to the preset opening adjustment range. Specifically, after the temperature and pressure conditions in the waste heat recovery system reach the conditions for the turbine expander to start, the turbine outlet valve (second control valve) is opened, and then the turbine inlet valve (fourth control valve) is gradually opened (generally 5% opening per second, which needs to be adjusted appropriately according to the actual situation) and the turbine bypass valve (third control valve) is gradually closed (generally 5% opening per second, which needs to be adjusted appropriately according to the actual situation).

[0038] S33, when the turbine expander is working normally, the third control valve is completely closed, and the waste heat recovery system enters the power generation mode. Specifically, after observing the turbine expander to ensure it is working properly, completely close the turbine bypass valve (third control valve), and the waste heat recovery system enters the power generation mode.

[0039] After observing the turbine expander to ensure it is working properly, completely close the turbine bypass valve (third control valve), and the waste heat recovery system will enter the power generation mode.

[0040] S34, when the vehicle's operating conditions are stable at the target parameters, the waste heat recovery system adjusts to the power generation mode and maintains stable operation for a preset time, so that the power generation of the turbine expander is within a stable fluctuation range. Specifically, when the vehicle's operating conditions are stable at the target parameters, the waste heat recovery system needs to maintain stable operation for a period of time (e.g., 5 minutes) after adjusting to the power generation state. When the vehicle's operating conditions are stable at the target parameters, the waste heat recovery system needs to maintain stable operation for 5 minutes after adjusting to the power generation state. The power generation of its turbine expander is within a stable fluctuation range (generally ±1kW, which can be adjusted appropriately according to the performance of different expanders and the accuracy of the measurement and control system).

[0041] S35 adjusts the working fluid pump speed to obtain the changes in the operating performance parameters of the waste heat recovery system under different speeds within the safe operating range of the turbine expander.

[0042] Specifically, after the vehicle's operating conditions are stable at the target parameters, the waste heat recovery system needs to maintain stable operation for a period of time after being adjusted to the power generation state. Then, the working fluid pump speed is adjusted to obtain the changes in the operating performance parameters of the waste heat recovery system at different speeds within the safe operating range of the turbine expander. These parameters include, but are not limited to, the power generation of the turbine expander, the flow rate, pressure, and temperature of the working fluid and condensate circulating in the system pipeline.

[0043] In step S4, which is the system shutdown phase, the waste heat recovery system and the diesel engine vehicle are shut down after the performance test, thus ending the experiment. Specifically, this process involves: S41, after completing the performance test, gradually open the third control valve according to the preset opening adjustment range, and then gradually decrease the opening of the fourth control valve according to the preset opening adjustment range until the turbine expander stops and the second control valve is closed. Specifically, system shutdown requires the waste heat recovery system and the diesel engine to be slowly stopped. After completing the experimental task, gradually open the turbine bypass valve (third control valve), then gradually reduce the turbine inlet valve (fourth control valve) until the turbine expander stops, and then close the turbine outlet valve (second control valve).

[0044] S42, gradually reduce the vehicle speed until it stops, adjust the working fluid pump speed of the waste heat recovery system until the parameters of the waste heat recovery system are in the fourth preset range, stop the working fluid pump, close the first control valve and the third control valve, and open the first bypass control valve and the second bypass control valve. Specifically, the vehicle speed is gradually reduced until it stops. The working fluid pump speed of the waste heat recovery system is adjusted until the system flow rate, pressure, and temperature are within a reasonable range (fourth preset range). Then, the working fluid pump is stopped, and all start / stop valves (first control valve and third control valve) of each component of the waste heat recovery system are closed, while all bypass valves (first bypass control valve and second bypass control valve) are opened.

[0045] S43. After the experiment, it was confirmed again that the internal components and connecting pipes of the engine vehicle, waste heat recovery system, and measurement and control system were all normal. It was also confirmed again that the connecting pipes between the engine vehicle and the waste heat recovery system were all normal.

[0046] Specifically, it is necessary to check the reliability of the connections of each pipeline inside the waste heat recovery system to ensure there are no leaks or damages; check that each component of the waste heat recovery system is functioning normally; check that each valve of the waste heat recovery system is in the closed state; and check the reliability of the rigid connections of each pipeline between the waste heat recovery system and the engine vehicle to ensure there are no leaks or damages.

[0047] It should be noted that the first preset range, the second preset range, the third preset range, and the fourth preset range in this embodiment are data ranges under different operating stages, which can be determined according to the overall vehicle operating conditions, i.e., the performance of each component of the waste heat recovery system. This embodiment of the invention does not impose any restrictions on these ranges.

[0048] The technical solution of this invention not only confirms that the internal components and connecting pipelines of the engine vehicle, the waste heat recovery system, and the measurement and control system are all normal, but also confirms that the connecting pipelines between the engine vehicle and the waste heat recovery system are all normal, thus ensuring the effectiveness of the experimental test of the waste heat recovery system test bench.

[0049] In this invention, the parameters of the organic working fluid and condensate circulating in the pipelines of the waste heat recovery system are checked to see if they are within a first preset range. After the check passes, the engine is started and the vehicle is run, the vehicle is set to idle, and the first bypass control valve and the second bypass control valve are closed. If the parameters of the organic working fluid and condensate circulating in the pipelines of the waste heat recovery system are within the first preset range, and the parameters in the pipelines connected to the engine and vehicle in the waste heat recovery system are within a second preset range, then the waste heat recovery system maintains stable operation before the engine and vehicle are started and at idle. The first pipeline parameter value is greater than the second pipeline parameter value. The first pipeline parameter value is the parameter value in the pipelines connected to the engine and vehicle in the waste heat recovery system when the vehicle is not running; the second pipeline parameter value is the parameter value in the pipelines connected to the engine and vehicle in the waste heat recovery system when the vehicle is running. This allows for safe startup of the vehicle waste heat recovery system test bench and rapid vehicle entry into driving mode while maintaining stable operation of the waste heat recovery system.

[0050] In this invention, during vehicle operating condition adjustment, as the preheater and flue gas heat exchanger in the waste heat recovery system interact with the engine and the entire vehicle, the speed of the working fluid pump in the waste heat recovery system is simultaneously adjusted to accelerate the flow rate of the organic working fluid inside the waste heat recovery system. When the turbine expander is operating normally, the third control valve is completely closed, and the waste heat recovery system enters the power generation mode. When the vehicle operating conditions are stable at the target parameters, the waste heat recovery system maintains stable operation for a preset time after adjusting to the power generation mode, and the power generation of the turbine expander remains within a stable fluctuation range. By adjusting the working fluid pump speed, the changes in the operating performance parameters of the waste heat recovery system at different speeds within the safe operating range of the turbine expander are obtained. The waste heat recovery system can then enter the power generation mode and follow the changes in its operating parameters under different vehicle driving conditions, thereby ensuring that the vehicle and waste heat recovery system are in a safe, stable, controllable, and monitorable state throughout the entire experiment. Because the waste heat recovery vehicle experiment steps are complex, the system is coupled, and the scheme design is difficult, the correct experimental testing process and operating sequence are crucial; otherwise, experimental test failures or even component damage may occur.

[0051] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A test bench suitable for a vehicle waste heat recovery system, characterized in that, include: The system comprises an engine vehicle, a waste heat recovery system, and a measurement and control system. The preheater in the waste heat recovery system is connected to the hydraulic retarder pipeline in the engine vehicle via a rigid pipeline. The flue gas heat exchanger in the waste heat recovery system is connected to the exhaust gas outlet pipeline in the engine vehicle via a rigid pipeline. This system is used to control the opening and closing of each pipeline through valves in the waste heat recovery system and the engine vehicle to start and stop the system test bench. The measurement and control system is installed on the pipelines in the engine vehicle and the waste heat recovery system to acquire the operating parameters of the engine vehicle and the waste heat recovery system.

2. The test bench for a vehicle waste heat recovery system according to claim 1, characterized in that, The waste heat recovery system includes a preheater, a regenerator, a condenser, a flue gas heat exchanger, a turboexpander, a working fluid pump, and a storage tank. The preheater exchanges heat with the engine coolant flowing into the hydraulic retarder under the action of the organic working fluid exiting the regenerator. The flue gas heat exchanger exchanges heat with the high-temperature exhaust gas emitted by the engine under the action of the organic working fluid exiting the preheater. The turboexpander performs work under the action of the organic working fluid exiting the flue gas heat exchanger and transports the heat-exchanged organic working fluid to the regenerator, outputting mechanical or electrical energy through work. The working fluid pump pumps the organic working fluid stored in the storage tank into the regenerator. The regenerator receives heat from the high-temperature organic working fluid at the outlet of the expander and transports the recovered heat to the condenser for condensation. The condenser condenses the organic working fluid at the outlet of the regenerator and transports the condensed organic working fluid to the storage tank.

3. The test bench for a vehicle waste heat recovery system according to claim 2, characterized in that, The measurement and control system includes a power analyzer, control valves, and parameter acquisition sensors. The power analyzer is used to monitor and analyze the work done by the turbine expander. The control valves include a first control valve located in the pipeline between the liquid storage tank and the working fluid pump; a second control valve located in the pipeline between the turbine expander and the regenerator; a third control valve located in the turbine expander bypass pipeline; a fourth control valve located in the pipeline between the flue gas heat exchanger and the turbine expander; a first bypass control valve located in the flue gas heat exchanger bypass pipeline in the engine vehicle; and a third control valve located in the preheater bypass pipeline in the engine vehicle. The second bypass control valve, wherein the parameter acquisition sensors are respectively installed in the pipeline between the preheater and the engine vehicle, the pipeline between the preheater and the hydraulic retarder, the pipeline between the flue gas heat exchanger and the engine vehicle, the pipeline between the preheater and the flue gas heat exchanger, the pipeline between the flue gas heat exchanger and the turbine expander, the pipeline between the turbine expander and the regenerator, the pipeline between the regenerator and the preheater, the pipeline between the working fluid pump and the regenerator, the pipeline between the regenerator and the condenser, and the pipeline between the condenser and the liquid storage tank.

4. A test method suitable for a test bench of a vehicle waste heat recovery system, characterized in that, Based on the experimental bench for a whole vehicle waste heat recovery system as described in any one of claims 1-3, it includes: Obtain the inspection status of the engine vehicle, waste heat recovery system, and measurement and control system internal components and connecting pipelines; obtain the inspection status of the connecting pipelines between the engine vehicle and the waste heat recovery system; confirm that the connecting pipelines between the engine vehicle and the waste heat recovery system are all normal. Start the diesel engine and run the vehicle, set the vehicle to idle, until the waste heat recovery system maintains stable operation before the engine is started and at idle. Adjust the vehicle's operating parameters to the target operating conditions, and test and record the waste heat recovery system. After the performance test is completed, the waste heat recovery system and the diesel engine of the vehicle will be shut down to end the experiment.

5. The test method for a test bench suitable for a vehicle waste heat recovery system according to claim 4, characterized in that, The confirmation that the engine, vehicle, waste heat recovery system, and internal components and connecting pipelines of the measurement and control system are all normal, and the confirmation that the connecting pipelines between the engine and vehicle and the waste heat recovery system are all normal, specifically includes: The engine and vehicle technical inspection results confirmed that the overall vehicle condition was good, and at least one vehicle testing software diagnosed the vehicle as having no faults. The inspection results of the connecting pipelines of each component in the waste heat recovery system showed no obvious leakage or damage, and the inspection results of the electrical wiring and signal acquisition of each component in the waste heat recovery system showed that the functions were normal. The inspection results of all components in the measurement and control system show that the equipment functions normally. The inspection results of the connecting pipeline between the waste heat recovery system and the engine vehicle showed no obvious leakage or damage; The waste heat recovery system and the control valves in the engine and vehicle are in the preset open / closed state.

6. The test method for a test bench suitable for a vehicle waste heat recovery system according to claim 5, characterized in that, The preset open / closed states are whether the first control valve, the second control valve, the third control valve, and the fourth control valve are in the closed state, and whether the first bypass control valve and the second bypass control valve are in the open state.

7. The test method for a test bench suitable for a whole vehicle waste heat recovery system according to claim 4, characterized in that, The process of starting the diesel engine and running the vehicle, setting the vehicle to idle speed, and ensuring the waste heat recovery system maintains stable operation before engine startup and during idle speed specifically involves: Open the first and second control valves in the waste heat recovery system in sequence and start the working fluid pump. Check whether the parameters of the organic working fluid and condensate circulating in the pipeline of the waste heat recovery system are within the first preset range. After the inspection results are passed, start the engine and run the vehicle. Set the vehicle to idle and close the first bypass control valve and the second bypass control valve. Check whether the parameters in the pipelines connected to the engine and vehicle in the waste heat recovery system are within the second preset range. If the parameters of the organic working fluid and condensate circulating in the pipelines of the waste heat recovery system are within the first preset range, and the parameters in the pipelines connected to the engine and vehicle in the waste heat recovery system are within the second preset range, then the waste heat recovery system will maintain stable operation before the engine and vehicle are started and at idle speed. The parameter values ​​in the pipelines connected to the engine and vehicle in the waste heat recovery system are greater than the parameter values ​​in the pipelines when the engine and vehicle are running.

8. The test method for a test bench suitable for a vehicle waste heat recovery system according to claim 4, characterized in that, Adjusting the vehicle's operating parameters to the target conditions, and testing and recording the waste heat recovery system, specifically including: During the vehicle operation condition adjustment, as the heat exchangers of the preheater and flue gas in the waste heat recovery system interact with the engine and the whole vehicle, the speed of the working fluid pump in the waste heat recovery system is adjusted synchronously to accelerate the flow rate of the organic working fluid inside the waste heat recovery system, thereby maintaining the parameters of the organic working fluid and condensate circulating in the pipeline of the waste heat recovery system within the third preset range. Once the parameters of the organic working fluid and condensate circulating in the pipeline of the waste heat recovery system meet the start-up conditions of the turbine expander, open the second control valve, gradually open the fourth control valve according to the preset opening adjustment range, and gradually close the third control valve according to the preset opening adjustment range. When the turbine expander is working normally, the third control valve is completely closed, and the waste heat recovery system enters the power generation mode. When the vehicle's operating conditions are stable at the target parameters, the waste heat recovery system maintains stable operation for a preset time after adjusting to the power generation mode, and the power generation of the turbine expander is within a stable fluctuation range. Adjust the working fluid pump speed to obtain the changes in the operating performance parameters of the waste heat recovery system under different speeds within the safe operating range of the turbine expander.

9. A test method for a test bench suitable for a vehicle waste heat recovery system according to claim 8, characterized in that, The operating performance parameters of the waste heat recovery system include the power generation of the turbine expander, the parameters of the organic working fluid and condensate circulating in the pipelines of the waste heat recovery system.

10. A test method for a test bench suitable for a vehicle waste heat recovery system according to claim 4, characterized in that, After the performance test is completed, the waste heat recovery system and the diesel engine of the entire vehicle will be shut down to end the test. Specifically: After completing the performance test, the third control valve is gradually opened according to the preset opening adjustment range, and then the opening of the fourth control valve is gradually reduced according to the preset opening adjustment range until the turbine expander stops and the second control valve is closed. Gradually reduce the vehicle speed until it stops. After adjusting the working fluid pump speed of the waste heat recovery system to the fourth preset range, stop the working fluid pump and close the first and third control valves. Open the first and second bypass control valves. After the experiment, it was confirmed again that the internal components and connecting pipelines of the engine vehicle, waste heat recovery system, and measurement and control system were all normal, and the connecting pipelines between the engine vehicle and the waste heat recovery system were also confirmed to be normal.

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